Kit# 521229-1 Mounting Bracket Kit Installation Instructions

Transcript

ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 fax 360-735-9300 www.roadmasterinc.com D M A S T E R , I N C. MOUNTING BRACKET KIT KIT# 521229-1 05/31/05 INSTALLATION INSTRUCTIONS RV Item Qty. Length Width Description Part# 1 .............. 1 ............... 1 1/2" ....... 1/2" ........... BOLT ................................................. 350095-00 A 2 .............. 1 ................................. 1/2" ........... LOCK WASHER ................................ 350309-00 3 .............. 4 ............... 110mm .... 8mm ......... 8mm x 1.25 x 110mm BOLT ............. 356009-00 4 .............. 4 ................................. 8mm ......... LOCK WASHER ................................ 355705-00 O 5 .............. 4 ................................. 8mm ......... FENDER WASHER ........................... 355702-00 6 .............. 2 .................................................... CABLE CONNECTOR ...................... 200008-00 7 .............. 2 ............... 8" ................................ SAFETY CABLE ............................... 500646-08 R FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DEATH, PERSONAL INJURY OR PROPERTY DAMAGE MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 KIT# 521229-1 fax 360-735-9300 05/31/05 RV www.roadmasterinc.com IMPORTANT: All brackets must be assembled with all the bolts left loose for final adjustment & positioning (before tightening) unless otherwise instructed. All bolts must be torqued for proper strength. If more than one bolt is used per fastening point, the diagram may only show one. • Use flat washers over all slotted holes • Use lock washers on all fasteners Item 1 .............. 2 .............. 3 .............. 4 .............. Qty. Part # 1 ............... C-001258 1 ............... C-001259 1 ............... C-001260 1 ............... C-001261 ....... ....... ....... ....... Description MAIN RECEIVER BRACE WELDMENT DRIVER SIDE ARM TUBE PASSENGER SIDE ARM TUBE THREADED BACKING PLATE ROADMASTER Limited Warranty, including One-Year Conditional Warranty Text and Product Registration Card, in Carton. WARNING Failure to follow these instructions can result in property damage, personal injury or even death. • Installation of most mounting brackets requires moderate mechanical aptitude and skills. We strongly recommend professional installation by an experienced installer. • The installer must read the instructions and use all bolts and parts supplied. When the instructions require the reuse of factory bolts, thread lock and/or lock washers must also be used. Failure to securely fasten the bracket could result in loss of the towed vehicle. • Do not use this document for custom fabrication, as it may not show all parts or structural components. Custom fabrication or an attempt to copy this bracket design could result in loss of the towed vehicle. • Every 3,000 miles, the owner must inspect the fasteners for proper torque, according to the bolt torque requirements chart on the last page of these instructions. The owner must also inspect all mounts and brackets for cracks or other signs of fatigue every 3,000 miles. Failure to do so could result in loss of the towed vehicle. • The owner must check the vehicle manufacturer's instructions for the proper procedure(s) to prepare the vehicle for towing. Some vehicles must be equipped with a transmission lube pump, an axle disconnect, driveline disconnect or free-wheeling hubs before they can be towed. Failure to properly equip the vehicle will cause severe damage to the transmission. • If running changes were made by the vehicle manufacturer after this bracket was designed, some bolts or other fasteners in the hardware pack may no longer be the correct size. It is the installer’s responsibility to verify that the bracket is securely fastened to the vehicle and fitted with the correct hardware to account for these changes. Failure to securely fasten the bracket could result in loss of the towed vehicle. • If the towed vehicle has been in an accident, it must be properly repaired before attaching the bracket. Do not install the bracket if any structural frame damage is found. Failure to repair the damage could result in the loss of the towed vehicle. • Some motorhome chassis have such a tight turning radius that you can damage your motorhome, towed vehicle, tow bar or bracket while turning sharply. Before getting on the road, test your turning radius in an empty parking lot. Turning too sharply could result in non-warranty damage to towing system, motorhome and/or towed vehicle. • Do not back up with the towed vehicle attached or non-warranty damage will occur to your towing system, motorhome and/or towed vehicle. • The safety cables must connect the towing vehicle to the towed vehicle frame to frame, with the cables crossed, with enough slack for sharp turns. Refer to the cable instructions for proper routing. Failure to leave enough slack in the safety cables, or failure to connect the safety cables frame to frame, will result in the loss of the towed vehicle. • This bracket is designed for use with ROADMASTER tow bars and ROADMASTER adaptors only. Using this bracket with other brands, without an approved ROADMASTER adaptor, may result in nonwarranty damage or injury. • Upon final installation, the installer must inspect the bracket to ensure adequate clearance, particularly around hoses, air conditioner lines, radiators, etc., or non-warranty damage to the towed vehicle will result. • This bracket is only warranteed for the original installation. Installing a used bracket on another vehicle is not recommended and will void the warranty. KIT# 521229-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 05/31/05 RV fax 360-735-9300 www.roadmasterinc.com T his is one of our EZ series brackets, which allows the Fig.A visible front portion of the brackets to be easily removed from the front of the vehicle (Fig.A and Fig.B). The bracket consists of a main receiver brace, two removable front braces and a hardware pack. The main receiver brace mounts to the bumper core and the frame rails. The tubular front braces are inserted into the main receiver brace and rotated 90 degrees to lock them in place. Before starting the installation, lay out the kit components in order, as they will be used. This will give you a visual idea of how the components work, and will also confirm that everything is present and accounted for. 1. Important: please use all supplied bolts and parts and Fig.B read all instructions carefully before beginning this installation. The majority of questions you may have can be answered within the text, and proper installation will ensure safe and secure travel. Now, begin the installation. Start by removing two T27 Torx bolts attaching the grille to the fascia (Fig.C). 2. Next, remove the hood latch release — first, pull up on the retainer clip. Then, insert a screwdriver between the plastic blades and pry them apart (Fig.D). 3. Pull up on the grille, releasing the tabs on either side, and remove the grille. 4. Remove four T27 Torx bolts holding the fascia to the core support (Fig.E). Fig.C Fig.D Fig.E Fig.G q fascia to fender q q q fender liner to fascia Fig.F Fig.H 5. On each side, remove four T25 Torx screws, one holding the fascia to the fender, and three holding the fender liner to the fascia (Fig.F). 6. From the bottom of the vehicle, remove three metal fasteners across the front of the fascia, holding the front of the fascia to the radiator support (Fig.G). 7. Pull forward on each side of the fascia to detach it. Unplug the side marker lights (Fig.H) and fog lights (if the vehicle is so equipped) on each side, and then remove the fascia. KIT# 521229-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 05/31/05 RV fax 360-735-9300 www.roadmasterinc.com Fig.K Fig.I Fig.J 8. On each side, remove the 18mm (head) nut on the bolt which is holding the bumper core to the bumper support (Fig.I). 9. Remove the two lower bumper support mounting bolts (T45 Torx head) on each side (Fig.J). 10. Before fitting the main receiver brace, trim a section of the air deflectors (on each side) so that the brace will fit over the air deflectors. Hold the main receiver brace over the air deflectors and trim enough material to accommodate the brace. Figure K shows the approximate amount to trim from each air deflector. Fig.L Fig.N Fig.M 11. Lift the main receiver brace up into place, so that the pre-drilled holes at each end of the main receiver brace align over the bolts holding the bumper core to the bumper support (Step 8). Apply thread lock to the factory nuts you removed in Step 8 and screw them back into place (Fig.L). Finger-tighten only at this time. 12. Attach the main receiver brace to the frame rails — Apply thread lock to the four supplied 8mm x 1.25 x 100mm bolts. Then, on each side of the main receiver brace, screw two of the bolts, with flat washers and lock washers, through the pre-drilled holes in the main receiver brace and into the holes for the bolts you removed in Step 9, and then through the bumper support and into the frame rail (Fig.M) 13. Torque all bolts to the specifications at the bottom of these instructions. 14. Attach the center of the main receiver brace to the bumper core — Using the hole in the center of the main receiver brace as a template, drill a ½" hole through the bumper core (Fig.N). 15. From behind the bumper core, position the supplied ¼" x 1-1/8" x 3" nutted backing plate so that the hole in the backing plate aligns over the hole you drilled in the preceding step. Use the supplied ½" x 1¼" bolt and lock washer to secure the backing plate in place (Fig.O). Fig.O All illustrations and specifications contained herein are based on the latest information available at the time of publication approval. ROADMASTER, INC. reserves the right to make changes at any time without notice in material, specification and models or to discontinue models. KIT# 521229-1 MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 05/31/05 RV fax 360-735-9300 www.roadmasterinc.com Fig.P q Trim grille q q Remove two horizontal ribs. Fig.Q Fig.R 16. Before re-attaching the fascia, trim both side grilles so that the removable front braces can extend through them. First, remove the side grilles by pulling forward on them. On the driver side, remove two horizontal ribs as indicated in Figure P, plus a small area indicated in orange. On the passenger side, remove one horizontal rib (Fig.Q). Next, using a die grinder and/or a hole saw, cut away the area indicated in Figure R on each side grille. 17. Reattach the fascia, reversing steps 1 through 7. 18. Insert the front braces into the main receiver brace and twist each one 90 degrees to lock. Attach the safety cables with the cable connectors (Q-Links) to the front of the receiver braces (Fig.S). Attach the ends of the safety cables to the tow vehicle's safety cables and tow bar. 19. Install the tow bar to the mounting bracket according to the manufacturer's instructions. Fig.S BOLT TORQUE REQUIREMENTS Note: The torque values represented below are intended as general guidelines. Torque requirements for specific applications may vary. Roadmaster does not warrant this information to be accurate for all applications and disclaims all liability for any claims or damages which may result from its use. STANDARD BOLTS Thread Size Grade METRIC BOLTS Torque 5/16 ................... 5 ......................... 13 3/8 ...................... 5 ......................... 23 7/16 ................... 5 ........................ 37 1/2 ...................... 5 ........................ 56 5/8 ...................... 5 ...................... 150 ft./lb. ft./lb. ft./lb. ft./lb. ft./lb. Thread Size Grade 8mm-1.0 ......... 8mm-1.25 ....... 10mm-1.25 ..... 10mm-1.5 ....... 8.8 8.8 8.8 8.8 METRIC BOLTS Plated / Unplated ....... 20 ft./lb. ....... 19 ft./lb. ...... 38 ft./lb. ...... 37 ft./lb. 18 18 36 35 ft./lb. ft./lb. ft./lb. ft./lb. Thread Size Grade 12mm-1.25 ..... 12mm-1.5 ....... 12mm-1.75 ..... 14mm-2.0 ....... 8.8 8.8 8.8 8.8 Plated / Unplated ....... 70 ft./lb. ....... 66 ft./lb. ...... 65 ft./lb. .... 104 ft./lb. 65 61 60 97 ft./lb. ft./lb. ft./lb. ft./lb. All illustrations and specifications contained herein are based on the latest information available at the time of publication approval. ROADMASTER, INC. reserves the right to make changes at any time without notice in material, specification and models or to discontinue models.